The future of aluminium processing industry: The facilities of tomorrow, now

The aluminium processing industry must be able to adapt to the fast-changing environment we are facing nowadays. With the aim of helping the aluminium industry in this non-stop adaptation, Insertec is working on the definition of tomorrow´s aluminium processing facilities, focusing on three key areas: efficiency, sustainability & knowledge.

Efficiency: Efficiency goes far beyond having a plant that respects emission regulations or monitoring energy consumption. Being efficient in 2023 means making the most of the full potential of a facility: achieving optimal profitability without losing sight of the well-being of people and the protection of the environment.

Our automation department is focusing on two strategic lines to achieve the most efficient facilities:  robotics and data intelligence.

Thanks to the first, we are going to achieve, apart from the automation of the processes, a minimum intervention of the operators in critical operations, as well as remote and real-time process monitoring.

Data intelligence, a perfect combination between artificial intelligence and machine learning, helps us to process huge amounts of information coming from different areas. Combining different sources of information, we get a powerful real-time facility managing tool. 

Both working lines represent an incredible advance in plant efficiency, a giant step that we are already taking, together with strategic partners, with the development of solutions such as the LAU Intelligent System, IFI Robotic Process and initiatives for the incorporation of disruptive technologies in the world of metallurgy such as the digital twin of equipment and production plants.

Sustainability: Nowadays, sustainability must be an integral part of the company, not only in its production process but also in its day-to-day activities. We have been reinventing ourselves in this sense for the last few months.

Moving towards a more environmentally friendly industry is a responsibility Insertec has been working on for some time. Internally, the company has taken a number of measures, such as digitizing catalogues and installing solar panels. But it invests significant effort and time in researching projects related to the circular economy at European and international levels. The company is involved in projects such as waste heat recovery through using heat exchangers at Etekina, using green hydrogen in combustion systems at H2-Site and H-Acero, and decarbonising production equipment in collaboration with Iberdrola.

However, we are convinced that the recovery and reuse of waste will be the key to achieve the sustainability objectives set. It is something that we are working on from our two business divisions. Our Refractory division is involved in a project to transform a secondary aluminum oxide into an alternative raw material to bauxites www.bauxal.com At Thermal Engineering Solutions division, we work on developing facilities and equipment capable of taking advantage of the full potential of post-consumer scrap in all phases of the process, producing low carbon footprint aluminum.

Knowledge:  Aluminium Metallurgy, Manufacturing Processes and Plant engineering are the strengths of our organization, essential knowledge to meet the demands of a profitable and sustainable economy.

Insertec was founded more than four decades ago with a singular goal: to improve existing industrial processes. Today, the company has become a household name, adapting to the demands of the industrial heat sector by manufacturing top-notch equipment and refractory materials.